Method of assembling a stator for an electric motor

Abstract

The apparatus of the present invention provides a stator for an electric motor. The apparatus includes a plurality of stator components assembled together to form a generally annular stator core. A wire is wrapped around at least a portion of the stator core to form a stator winding. A first generally annular end plate and a second generally annular end plate are mounted to axially opposite sides of the stator core such that the stator core is axially trapped and retained therebetween. A fastener applies a clamping load to the first and second end plates such that the stator core is compressed therebetween. The clamping load from the fastener is applied directly to the first and second end plates which distribute the clamping load to the stator core such that the plurality of components are held together without the fastener directly applying the clamping load to the stator core. A corresponding method for providing a stator is similarly provided.

1. A method for assembling a stator for an electric motor comprising:
 providing a plurality of stator components composed of generally insulated ferromagnetic particles, said plurality of stator components including a plurality of alignment protrusions and a plurality of alignment depressions; 
 assembling said plurality of stator components such that at least a portion of said alignment protrusions and said alignment depressions engage to align said plurality of stator components and form a stator core; 
 wrapping a wire around at least a portion of the stator core to form a stator winding; 
 providing a first generally annular end plate and a second generally annular end plate; 
 mounting said first and second end plates to axially opposite sides of said stator core such that said stator core is axially trapped and retained therebetween; 
 applying a clamping load to the first and second end plates with a fastener such that the stator core is compressed therebetween; 
 wherein said clamping load from said fastener is applied to said first and second end plates which distribute the clamping load to the stator core such that the plurality of components are held together without said fastener directly applying the clamping load to the stator core. 
 
     
     
       2. The method of  claim 1 , wherein said providing a first and second generally annular end plate includes providing a first and second generally annular end plate having a plurality of projections and/or depressions configured to facilitate the alignment of the first and second end plates relative to the stator core. 
     
     
       3. The method of  claim 2 , further comprising providing a first annular member disposed between the first end plate and the stator core, and a second annular member disposed between the second end plate and the stator core, wherein said first and second annular members are configured to distribute the clamping load from the fastener to the stator core. 
     
     
       4. The method of  claim 2 , further comprising providing an adhesive disposed between the first end plate and the stator core, and between the second end plate and the stator core, wherein said adhesive is configured to hold the plurality of components together with a reduced fastener clamping load. 
     
     
       5. The method of  claim 2 , wherein said providing a plurality of stator components includes providing a plurality of center segments and a plurality of end segments.